Portable Welding Torch Alignment for Consistent Anchor Rod Welds
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Solution Overview
Problem
Manual welding for large construction projects is laborious, time-consuming, and can lead to mobility, health, and ergonomics issues, while existing automated devices are not easily portable and require objects to be brought to the welding device.
Innovation Solution
A portable welding tool with a rotating welding torch and a locating device that positions objects to be welded on a welding axis, allowing for rapid and accurate production of multiple welds, and a controller to automate the welding process, enabling operation by a laborer without the need for a qualified welder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated welding devices are used, then welding quality consistency is improved, but portability deteriorates
Solution Approach 1:
The welding system is divided into separate functional modules: a portable welding torch assembly that can be easily moved to different locations, and a separate control system that can remain stationary or be relocated as needed. This segmentation allows the welding torch to be portable while the automated control provides consistent welding quality.
Solution Approach 2:
A portable control unit or remote control system acts as an intermediary between the operator and the welding torch. This allows automated welding processes to be controlled from a portable position, maintaining both portability and welding consistency through electronic control signals.
2Stability of the object's composition
If objects are brought to the welding device, then welding stability is improved, but operational flexibility deteriorates
Solution Approach 1:
Instead of bringing objects to the welding device, the welding device is brought to the objects. The welding torch is designed to be portable and can be moved to different work locations, while the locating device ensures stable positioning once arrived. This inversion maintains welding stability through the locating mechanism while achieving operational flexibility through portability.
Solution Approach 2:
The traditional mechanical approach of moving heavy welding equipment to objects is replaced with a lighter, more portable welding torch design. Electronic control systems and battery power replace heavy mechanical welding machines, enabling the welder to move freely to different objects while maintaining welding stability through controlled positioning.
3Measurement precision
If a locating device is extended toward the welding axis, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The locating function is extracted as a separate, dedicated device rather than being integrated into the main welding torch structure. This locating device can be a simple mechanical fixture or positioning aid that attaches to or near the welding area, providing precise positioning without adding complexity to the core welding system.
Solution Approach 2:
The locating device creates a simplified geometric representation or template of the desired weld position. By using a physical template, jig, or marking system that copies the required positioning geometry, precise positioning is achieved through simple geometric alignment rather than complex measurement and calculation systems.
Data Source
AI summary
A welding tool includes a tool support and a welding torch coupled to the tool support. The welding tool is configured to rotate relative to the tool support about a welding axis. A locating device is coupled to the tool support and is movable between a retracted position and an extended position. In the extended position, the locating device extends toward the welding axis. The locating device includes a recess at an end of the locating device. The recess is configured such that, when a predetermined object to be welded (such as an anchor rod) is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.